Ing. Peter Hofmann

Autoreferát dizerta čnej práce

Ways of improving energy efficiency in small and medium- sized enterprises

na získanie akademickej hodnosti doktor (philosophiae doctor, PhD.)

v doktorandskom študijnom programe: Elektroenergeti ka

v študijnom odbore 5.2.30 Power Engineering

Forma štúdia externá

Miesto a dátum: Bratislava, 24.06.2017

SLOVENSKÁ TECHNICKÁ UNIVERZITA

V BRATISLAVE

FAKULTA ELEKTROTECHNIKY A INFORMATIKY

Ing. Peter Hofmann

Autoreferát dizerta čnej práce

Cesty k zvyšovaniu energetickej efektívnosti v SME

na získanie akademickej hodnosti doktor (philosophiae doctor, PhD.)

v doktorandskom študijnom programe:

Elektroenergetika

Miesto a dátum: Bratislava, 24.06. 2017

2

Dizerta čná práca bola vypracovaná v externej forme doktorandského štúdia

Na: Ústav elektroenergetiky a aplikovanej elektrotechniky,Fakulta elektrotechniky a informatiky Slovenská technická univerzita v Bratislave

Predkladate ľ: Ing. Peter Hofmann, Ústav elektroenergetiky a aplikovanej elektrotechniky, Fakulta elektrotechniky a informatiky, Slovenská technická univerzita v Bratislave

Školite ľ: Prof. Ing. Vladimír Šály, PhD. IPAEE FEEIT, Ilkovičova 3, 81219 Bratislava

Slovenská technická univerzita v Bratislave

Oponenti: Prof. Ing. Iraida Kolcunová, PhD., KEE, Fakulta elektrotechniky a informatiky TU Košice, Mäsiarska 74, 041 20 Košice

Ing. Zdenek Dostál, CSc. Inšitút Aurela Slobodu, Univerzita Žilina ul. kpt. J. Nálepku 1390, 031 01 Liptovský Mikuláš

Autoreferát bol rozoslaný:

Obhajoba dizerta čnej práce sa koná:

Na Fakulta elektroniky a informatiky Slovenská technická

univerzita v Bratislava, Ilkovičova 3

prof. Dr. Ing. Miloš Oravec dekan FEI STU

3

3

1

Thesis and purpose of the dissertation Introduction / Obsah

4

5

1.1 Problem Situation

5

1.2 Definition of key terms 6

1.2.1 Energy and energy efficiency 6

1.2.2 Small and medium-sized enterprises in Germany 7

1.3 Eco political necessities and energy reversal

7

2 Research method

8

2.1 Principle way to energy efficiency 8

2.2 Technical and methodological measurement 9

2.3 Economic efficiency and amortization of refurbishment measures

10

2.4 Strategic measures to increase energy efficiency

10

2.4.1 Applications in companies 10

2.4.2 Building physical measures 10

2.4.3 Technical measures 11

2.4.4 Organizational measures

11

2.5 Theses and objectives of dissertation 12

2.6 Introduction of the investigated existing company 14

2.6.1 Typification of the building and structure 14

2.6.2 Energy consumption (actual state)

15

3 Results and discussion of the study

16

3.1 Developed standardized, strategic phase model 16

3.2 The energy turnaround /reversal of the investigated company 19

3.3 Developed energy storage system for the investigated company 22

3.4 Identified supporting and inhibiting factors in the context of energy efficiency measures

26

4 Conclusion and outlook

27

List of author´s publications

List of sources

4

Thesis and purpose of the dissertation

This thesis corresponds in objective and content, in particular of solutions for

current and possible future-oriented questions of the practice. So the attempt

is made to provide recommendations on principle suitable options for

increase energy efficiency.

Practice-relevant conclusions should be derived. Additional the results should

initiate further applications, publications and research.

1. Development and design of an standardized, strat egic phase model

for increasing energy efficiency in small and m edium sized

companies.

2. Optimization with an energy turnaround /reversal using the example

of the investigated medium- sized company.

3. Identification and development of an energy sto rage system in case

of an holistic renewable energy aproach for the investigated

medium- sized company.

4. Identification of supporting and inhibiting fact ors in the context of

energy efficiency measures in small and medium size d companies.

As the result that shoud lead to:

The combination of theoretical model and practical data as a representation

of reality.

The formula would be: Theoretical model + practical data = real model

5

1 Introduction 1.1 Problem Situation

Energy is a topic of the future.

Climate change and rising energy costs are now increasingly in the public

and political debate.

The energy that is used in the companies is still wasted to a considerable

extent and causes disproportionately high environmental impacts and costs.

Topics that describe the energy efficiency of companies and their

remediation possibilities have gained a permanent place in the engineering

journals.

The energetic structures in the companies are becoming more and more

complex.They are in an increasingly tighter web of dependencies and

interactions. Those who have to make forward-looking decisions in this

situation are dependent on quality informations and advice.

Without concept implemented individual measures do not lead to the desired

result, and only reinforce the widespread skepticism about energy

refurbishment measures.

Additional the technical possibilities are now very extensive, often leading to

enlargement of the insecurity. Complete avoidance is often the result.

These factors are therefore also a growing scientific and engineering

challenge.

Because the optimization process is usually distributed not only on one single

measure, but on several pillars within a continuous improvement process.

The result should be a "tailor-made specific company suit" with regard to

building physics and systems engineering as well as the costs and therefore

its optimum of the energetic and economic efficiency.

The five groups of efficient energy use measures are: 1. Avoidance of unnecessary consumption 2. Improved efficiency rates 3. Recovery of energy 4. Using renewable energies 5. Energy controlling (compare Bayerisches Landesamt für Umwelt, 2009, “Leitfaden für effiziente Energienutzung in Industrie und Gewerbe“ p.8 ) [1]

6

1.2 Definition of key terms

1.2.1 Energy and energy efficiency

Energy can neither be created nor consumed but always only transformed

from one form to another. In the very last consequence all the energy

originates from the sun.

Primarily energy demand:

Final energy taking into account the energy needs of the preceding process

chains such as extraction, transportation, processing and conversion of

primary energy carriers.

Useful energy:

Energy at the end of a conversion chain available to the consumer for various

applications for example light, heat or mechanical energy.

(see also Recknagel, Sprenger, Schramek 2003/ 2004 p.361) [2]

Grey energy: (indirect energy):

As embodied /grey energy (not renewable) primary energy is referred that is

needed to construct a building.

Embodied energy includes energy for the extraction of materials for the

manufacture and processing of components for the transportation of people,

equipment, components and materials to the building site, for installation of

components in the building as well as disposal. Through the use of local

materials and sustainable construction the built-in building embodied energy

can be minimized.

Compare: www.baunetzwissen.de/ graue energie (grey energy)

Efficiency:

Efficiency is understood in general in improving the yield or increased

utilization, reduce of losses and economic use (optimized use factor).In the

technical sense it means the ratio of benefit to effort (efficiency) and under

commercial consideration the ratio of earnings to the invested resources.

Energy Saving:

The best energy is that which is not “consumed” at all.

7

1.2.2 Small and medium- sized enterprises in German y

“The Institute for SME Research Bonn defines independent companies with

up to 499 employees and an annual turnover to less than 50 million € as

small and medium-sized enterprises (SMEs)” .European Commission defines

them only up to 250 employees.

Small- and medium-sized enterprises are widely regarded as the backbone

of the german economy, and stand out in comparison to large group

companies by greater flexibility and innovation dynamics and through greater

cooperation.

They are also the site of new business ideas. While large companies tend to

cut off jobs, they are created by SMEs.

„In a competitive international economy large enterprises ensure the survival

of the national economy, small and medium enterprises ensure the survival

of large companies, both together ensure the survival of the national

economy. The market economy itself provides the greatest welfare of the

people.“

(Source:Niehues, Dr.Karl, „Unternehmenserfolg statt hausgemachter Unternehmenskrisen“ KMU-Institut GmbH, Waldeyerstr. 61, 48149 Münster, 1997) [3] 1.3 Eco political necessities and energy reversal

Todays global population currently is about 7,3 billion people, of which only

about 1 billion is living in wealth. In addition there is a further annual growth

of about 80 million people. Fossil fuels such as coal, oil and natural gas are

not unlimited.

This naturally results in increasing energy prices. But their use is also

associated with some environmental problems. Viewing scientific studies

indicate that worldwide more than 24 billion tons of the greenhouse gas

carbon dioxide CO2 emitted into the atmosphere. This in turn results in

dramatic climatic changes or natural disasters.

Mainly responsible for this draw are the industrialized nations. They emit

about 80% of the greenhouse gases.

The last decade has been marked by growing public concern and

widespread media coverage surrounding the topic of global warming due to

an increased greenhouse effect process chain.

8

2 Reseach method

2.1 Principle way to energy efficiency

The development of a standardized phase model, which may also be

universal, taking into account industry-specific requirements, demands a

successive and structured procedure.

In addition further synergies can be achieved through a holistic

implementation. At its beginning in principle an initial consultation with an

energy consultant or an engineer of the relevant disciplines should take

place. After analysis i.e. determination of the actual state of the company and

its immanent potential, respectively the individual matching optimization

opportunities of the strategic action plan are prioritized, selected, and

energetically and economically compared, i.e. how they behave in the cost

and profitability comparison. Because the optimization process is usually not

only distributed to a single measure, but on multiple columns within a

continuous improvement process, it may be necessary to carry out the

success monitoring already for each of the individual measures.

That leads in a first approach to the following coarse expiration: Assessment of the actual state – Determined and formulated as precisely and detailed as possible.

Operationalization –

The terms and variables that are connected to the problem clarification, are

worked out and defined.

Data collection –

Measures are selected, and afterwards the measures are conducted and

documented.

Data analysis –

The data is sorted, analyzed and compacted in their meaningfulness by

various methods.

Choice of measures and method –

The method of choice arises from the target position as well as the specific

possibilities. Then the instruments are developed (check list, questionnaire,

etc.).

Presentation and controlling of results.

9

2.2 Technical and methodological measurement

The following calculations and measurements are to be done:

One of these measurement is the noncontact infrared thermometry.

In addition to this measurement there are also be measurements of the real

power and gas consumption, of air exchange rates, of burner efficiency and

room / system temperature levels, circulation pump speeds, etc. Due to the

fact that the wall areas of the building are the largest heat transfer surfaces

not only at this point is a particular importance, to verify the theoretically

calculated values through real measurements.

In the context of the detection of the actual state of the investigated company

this noncontact infrared thermometry will be applied. Where an actual

refurbishing measure is done, also a result control is performed. The building

physical measurements are performed using an infrared thermographic

camera and visually represented in the form of color gradation images (see

Pic.1).

Picture 1: Investigated company (actual state). View from east.

This "thermal images" indicate the regions with different surface

temperatures and heat radiated emissions on a building by various colour

gradations.

10

2.3 Economic efficiency and amortization of ene rgy refurbishment

measures

Rising energy costs burden increasingly the companies.

Economic efficiency calculations are used to assess the economic viability of

projects or measures. These are methods of calculation of the investments,

costs, revenues or profit of a project to determine financial parameters. The

comparison of these parameters then allows the decision for or against

specific projects or measures. Their aim, therefore, is to make statements

about the resulting benefit of a proposed investment decision. It is about the

optimization of alternative choices.

2.4 Strategic measures to increase energy effici ency

2.4.1 Applications in companies

Not all the companies have the same energy consumption structure. It

depends on their sector. Inter alia particularly high savings potentials occur in

the field of cross-cutting technologies:

They include all energy saving measures that can be used for all sectors

equally. They are sector independent.

All other measures are to be checked industry-specific regarding the individual case. 2.4.2 Building physical measures

All buildings in common have a continuous, energetic interaction with the

environment which leads to heat losses caused by transmission and building

leakiness. A crucial aspect of an energy-efficient building is the technical

quality of its thermal insulation and heat transfer components.

The optimal building envelope has essentially to satisfy the following requirements: - Lowest possible heat transfer coefficient , - Air and wind tightness, - Prevention of thermal bridges Possible measures i.a.: - Building insulation and thermographic weak point analysis, - Air tightness of buildings, - Hall doors, windows, skylights (improve or renew) - Solar protection of glass (reduction of air conditioning), - Daylight steering

11

2.4.3 Technical measures

The choice of technical measures can not considered isolated. They have to

be selected in each individual case on the basis of a holistic overall concept.

Here several factors such as the building physical conditions,the priorities,

local conditions, investment costs, life cycle costs, etc. are to be evaluated.

Measures i.a.:

- Combined heat and power (CHP), - Heating and condensing technology - Process heat optimization, - Biomass / Biogas, - Heat pump and zeolite technology - Efficient machines and motors, - Heat distribution and insulation, - Hydraulic balancing with lowest supply and return temperatures, - Concrete core tempering, - Ventilation technology (with heat recovery) - Efficient steam generation, - Air conditionig and chilling - Thermal solar technology, - Photovoltaics, - Hybrid collectors - Storage technology (electrical / thermal),- Efficient use of compressed air - Hydro power, - Wind power, - Water consumption / domestic water - Waste water recycling / heat recovery, - Drying technology - Logistics and transport, - Efficiency of light and illumination - Control, regulation- and communication technology / Smart metering - Information technology and office equipment

2.4.4 Organizational measures

Besides all the technical efforts to reduce the energy demand a prudent use

of energy plays also an important role. Often small adjustments in the

workflow or a deliberate switching off of unneeded equipment and systems

are already sufficient to reduce the energy costs. These organizational

measures require no or only minimal costs.

(see Dena GmbH, 2009 “Handbuch für betriebliches Energiemanagement“,

p.35) [4]

These are i.a.:

- Energy consultancy and public subsidization, - Optimization of energy purchasing - Increasing the kwowledge about energy efficiency in all company levels - Regularly technical maintenance, - Establishing of an energy manager, - Employee training in terms of energy efficient behaviour, - Predictive energy demand planning (i.a.using the weather forecast)

12

2.5 Theses and objectives of the dissertation wo rk

This thesis corresponds in objective and content, in particular of solutions for

current and possible future-oriented questions. Practice-relevant conclusions

should be derived. Additional the results should initiate further applications,

publications and research. Knowledge transfer is not only the transfer of

scientific knowledge out of competence areas of the university into business

practice, but also the transfer of practical issues and impulses towards

science.

1. Development and design of an standardized, strat egic phase model

for increasing energy efficiency in small and m edium sized

companies.

This first approach is a systematic identification that should be based on a

catalog of strategic measures, that even taking into account industry-specific

requirements through a successive and structured method.

As the result, an energy efficiency algorithm for small and medium sized

companies is to be evaluated that can be applied universally .

This strategic phase model is to be divided into operational steps to achieve

a defined aim with appropriately defined resources, investment etc.

It is a concept which combines methodological ,technical and economic

aspects within one integrative framework.The result is a "tailor-made specific

company suit " with regard to building physics and systems engineering as

well as the costs and therefore its optimum of the energetic and economic

efficiency.

2. Optimization with an energy turnaround /reversal using the example

of the investigated medium- sized company.

The second aim is the systematic application that should be based on the

previous evaluated strategic phase model for increasing energy

efficiency. As the result, the question is to be answered if it is possible

only by using of todays high efficiency and renewable energy

technologies to refurbish an existing company in the way that it

produces enough or more energy than it consumes. (Self sufficient

respectively autark or plus energy decentralized approach).

13

3. Identification and development of an energy sto rage system in case

of anholistic renewable energy aproach for the investigated

medium- sized company.

As infrastructure optimization respectively energy optimization is not the core

business of the manufacturing companies, the existing engineering

capabilities are often not optimal or used only with second priority.

Renovation and plant expansions, the energy supply is indeed adapted but a

holistic optimization is often not carried out, because these adjustments are

implemented gradually.

The objective of this analysis is to answer the question whether an approach

like described before is technically possible without an energy storage

system. Further it has to be checked whether such a system is cost-effective

that means that there is an appropriate economic efficiency.

4. Identification of supporting and inhibiting fact ors in the context of

energy efficiency measures in small and medium size d companies.

As mentioned before the energetic structures in the companies are becoming

more and more complex.They are in an increasingly tighter web of

dependencies and interactions. Those who have to make forward-looking

decisions in this situation are dependent on quality informations and advice.

Without concept implemented individual measures do not lead to the desired

result, and only reinforce the widespread skepticism about energy

refurbishment measures. Additional the technical possibilities are now very

extensive, often leading to enlargement of the insecurity. Complete

avoidance is often the result. For this reason, for an successful

implementation of energy efficiency measures it is necessary to identify these

supporting or inhibiting factors in the decision-making process.

As the result that shoud lead to:

The combination of theoretical model and practical data as a representation

of reality.

The formula would be:

Theoretical model + practical data = real model

The result of the research project will be a synthesis of theoretical model and

and practical application for an reciprocal knowledge transfer.

14

2.6 Introduction of the investigated existing comp any

2.6.1 Typification of the building and structure The investigated company building (see Pic.2) is a complex of halls

consisting of two production halls, a storage hall and a logistics center (hall)

each with office areas. Further connected is a wholesale area and an office

tower. The building is exploited by a surface treatment and lacquering

company with attached logistic center. The first hall was built in 1970.

Thereafter, the complex was successively extended until the eighties.

Location: Traffic favorable location in a commercial area in 35685 Dillenburg-

Manderbach, Dillenburg road 66-72 in Germany.

Land area: 29687 m²

Building area: 7135m²

Height above sea level: 270 m

Picture 2: The investigated company complex (actual state).View from south- west

15

Floor plan (see Fig. 1):

Figure 1: Floor plan of the whole building complex

Utilization: - Hall 1: Production / office,- Hall 2: Production, -Hall 2: Whole

sale /office, Hall 3: Logistic and distribution /office, Hall 4: Storage,

Tower: 1. floor: Office, 2. floor: Office

2.6.2 Energy consumption (actual state see Fig. 2)

Figure 2: Calculated results of the actual state

16

As clearly recognizable, the consumption of heating energy with 2.354.823

kWh per year (actual state) constitutes the largest part of the total energy

consumption. This results mainly from the bad building physical conditions as

well as the partially outdated plant technology. The rest is caused by the

illumination and small proportion even by the domestic warm water.

Moreover, in the diagrams of the primarily and final energy nor the ventilation

losses are included. The evaluation of the useful- energy consumption

statistics of the past 10 years revealed a gas consumption for heating on

average of 2.014.300 kWh per year (compare useful energy 2.354.823 kWh

per year).

As can be seen in Fig.2 (theoretical model calculation) there is a high

congruence between these results and its real consumption. (Average of the

last decade).

3 Results and discussion of the study 3.1 Developed standardized, strategic phase model The evaluation of the strategic phase energy efficiency model yielded the in

the (not yet used) following 5 steps algorithm that can be applied universally.

Figure 3: Developed 5 Steps Algorithm

17

Algorithm integration into applied software analysis:

Basically its course is based on the problem description followed by the

problem decomposition towards the problem solution.

The software includes the calculation and balancing of the entire building

physics and all currently available and state of the art plant technologies. The

integration of the applied 5 Steps Algorithm into the implemented software

analysis enabled thus an holistic approach. The results were calculated using

the integral approach of the standard DIN 18599 within the calculation kernel

of the Fraunhofer Institute. It took into account the mutual interactions

between building physics, standardized usage and plant technology.

The software was always used in compliance with the guidelines of this

algorithm.

Step 1: Assessment of the actual state Basis for the creation of the refurbishing concept is the

detection of the actual state. In this context, the energy status quo of the

company in terms of the existing plant technology, building physics, the

organizational situation as well as its energy demand was captured

detailed.

Step 2: Operationalization The objective and variables that are connected to the problem clarification,

are worked out defined to enable measurability.

Intented Result:

The combination of theoretical model and practical data as a representation

of reality. The formula would be: Theoretical model + practical data = real

modelThe result of the research project will be a synthesis of theoretical

model and and practical application for an reciprocal knowledge transfer.

The corresponding energy and economic calculations and simulations are to

be carried out. In addition, the use of appropriate technical tools such as,

inter alia, data logger, thermal imagers, tightness measurement equipement

have to be used.

18

Step 3: Data collection and analysis In order to ensure a comprehensive inventory a data inquiry sheet was

specifically developed. It is stored in the appendix. Then the instruments are

developed (check list, questionnaire, etc.). Measures are selected, and

afterwards the measures are conducted and documented.

Step 4: Choice of measures and methods The methods of choice arised from the target position as well as the specific

possibilities also taking into account all company-specific economic factors.

With regard to necessary clarification the following nine-field decision making

matrix was developed.

High energy

savings

I High savings

Low costs

II High savings

Medium costs

III High savings

High costs

Medium

energy savings

IV Medium savings

Low costs

V Medium savings Medium costs

VI Medium savings High costs

Low energy

savings

VII Low savings Low costs

VIII Low savings

Medium costs

IX Low savings

High costs

Low

investment costs

Medium

investment costs

High

investment costs

Figure 4: Developed nine-field decision making matrix

Economic efficiency calculations are used to assess the economic viability of

projects or measures. These are methods of calculation of the investments,

costs, revenues or profit of a project to determine financial parameters. The

comparison of these parameters then allows the decision for or against

specific projects or measures.

19

Step 5: Presentation and controlling of results

Central importance is the phase sequence, taking into account all the

energetic and economic factors must be strictly observed. This becomes

clear, if one imagines the entire optimization process as steps of a staircase

at whose end the final goal achievement is.In the first place the recognition

and weighting of the measures to be prioritized has to be done. In order to

achieve a holistic approach is the compliance with the order the remedial

measures taking into account all energy and economic factors of central

importance. For example, for the case of a replacement of the existing

heating boiler and subsequent optimization of the building physics.

In this case, the previously conducted, on the basis of the old or more worse

building physics, the calculation of the required performance of the new boiler

would have been led to an corresponding oversized system.

In the result i.e. taking into account the new and more efficient building

physics, the new boiler is significantly too large dimensioned and was equally

unnecessarily expensive.

3.2 The energy turnaround /reversal of the investig ated company As mentioned in chapter 2.6, and its result regarding the actual state

revealed clearly that the investigated company is not nearly state of the art.

For this reason, the question had to be asked if it is possible only with todays

state of the art technologies to refurbish an existing Enterprise in that way

that it produces enough or mor energy than it consumes. The choice of

technical measures were not considered isolated. They were selected in

each individual case on the basis of the developed standardized phase

model. Here several factors such as priorities, local conditions, investment

costs, life cycle costs, etc. were regarded as well. In this first step, an

approach was developed and calculated still without an storage system. An

even more advanced approach consisting of an efficient storage system in

combination with todays state of the art technologies including an 300 kWp

photovoltaic system was developed and calculated in the second step

described in section 3.3. In this first step, different models and variations

have been developed, simulated and calculated by which the energtic and

20

economically most efficient (still without storage system) is represented in its

result as explained below. Finally the following approach evealed as the best

system wit regard to energy saving and investment costs.

First optimization step: Building physical measures:

(simulated, calculated and partly already implement ed) Insulation of roof and outside walls, industrial glazing insulation with

transparent thermal insulation, skylights (roof) insulation with transparent

thermal insulation, solar protection of glass with sunshade slats (reduce of air

conditioning).The combination with an ventilation system made it possible to

avoid an active air conditioning system for the office tower. In addition, the

uppermost 6 slats can illuminate the room indirectly. About these the incoming

daylight is directed into the room. (Daylight steering)

Technical measures:

(simulated, calculated and partly already implement ed)

- Heating: 2 Combined heat and power system

3 Heat pumps ( both as replacement of the old gas- and oil-fired

low temperature boiler).

- Domestic water: Instantaneous electrical water flow heater

- Demand-controlled ventilation system with heat recovery

-The entire heating distribution system has been hydraulically balanced

(saving potential approx. 15 %), newly insulated and refurbished with ceiling

mounted radiant panels (replacement of the old fan heater).

They as well as the physical building measures enabled significantly lower

system temperatures. These supply- and return temperatures were

decreased from formerly 90/70° C to 50/40° C

- High efficiency circulation pumps

- Thermostatic with an additional a new energy harvesting system

- Efficient use of compressed air (sealed piping system and reduced system

pressure

- Information technology and office equipment with high-efficiency class A+++

(european energy label) equipement

21

- Photovoltaic power plant

The plant with nominal power output of 300 kWp is currently in the

construction phase.This plant has an annual electricity production in total of

294751 kWh. The calculated annual electricity demand of the whole

complexes is about 288679 kWh, so that there is in sum a theoretical

coincidence of production and consumption.

- Efficiency of light and illumination

All ligth systems (halls,offices and outside lighting) were replaced with LED

systems with presence detectors and automatic light shutdown.

Organizational measures:

(simulated, calculated and partly already implement ed)

- Introduction of an energy management system,

- Regularly technical maintenance

- Establishing of an energy manager (from the workforce of the company)

- Workforce and managemnt training in terms of energy efficient behaviour

- Energy benchmarking

- Best practice examples

- Energy management

- Predictive energy demand planning

- Optimization of energy purchasing

Energy consumption after first optimization:

Figure 5: Calculated results of the first optimization

22

As can be seen the primarily energy demand for the entire commercial park

after first optimization step decreased from 608 kWh/m²a to 87,6 kWh/m²a

(86 %). The total final energy demand decreased from 560,91 kWh/m²a to

70,45 kWh/m²a. Moreover, the use of the "energy-producing plants" the heat

pumps can be seen. For this reason, in this case the final energy is now

lower than the useful energy

Economic efficiency and amortization of energy refu rbishment

measures (first optimization):

Table 1: Economic efficiency and amortization calculation of first optimization 3.3 Developed energy storage system for the investi gated company The objective of this analysis is to answer the question whether an approach

like described before is technically possible without an energy storage

system. Further it has to be checked whether such a system is cost-effective

that means that there is an appropriate economic efficiency. Therefore a

suitable ice storage system was developed, simulated and calculated.The

buildings physical measures and illumination, photovoltaics etc. are

equal to the first optimization approach. Only those described below

are different from the first approach.

Actual annual fuel costs Actual State 259846,92 € First Step 23228,03 € Boundary conditions Calculatory interest rate 3% Inflation rates Fuel (actual state) 4 % Fuel (first step) 4 % Measures 3,5 % Maintenance 4,5 % Investment tax rate for fiscal depreciation 32 % Calculation parameters Observation period (years) 30 Averaging factors Fuel (actual state) Fuel (first step) Measures Maintenance

Results Investment Total Investment costs 2025863 € Costs of anyway necessary maintenance expenditure 448568 € Costs of energy saving measures 1577295 € Average annual costs of observation Period (30 years) Costs of capital 101559 €/ Year Costs of Fuel 41441 €/ Year Costs of maintenance + 47083 €/ Year Total costs 190083 €/ Year Av. costs of fuel without measures Average annual saving 273503 €/ Year Internal Interest 14,61 % The investment is economically. Its internal rate of return is higher than the calculatory interest rate Armortization time 9 Years Price of the saved kWh 0,0425€/kWh

23

Technical measures:

(simulated, calculated and partly already implement ed)

Heating: 1 Combined heat and power system

1 Biomass (pellets) heating system

As part of the evaluation of a suitable energy storage system for the

investigated company a variety of storage approaches were considered.

Ranging from the electrical energy storage systems, inter alia, the

electrochemical, compressed air or a power to gas (methane) approach.

In the field of thermal storage possibilities, taking into account their energy

density storage capacity, among others the possibilities of water reservoirs,

latent heat storage with phase change materials (PCM) or the

thermochemical storage systems for instance with sorption materials such as

zeolite were considered.

Energy balance: Commercial Park with Storage System (see Fig. 6)

Figure 6: Calculated results of the developed storage system

As can be seen the primarily energy demand for the entire commercial park

after first optimization step decreased from 608 kWh/m²a to 87,6 kWh/m²a

(86 %) and once again with a storage system to 35,4 kWh/m²a. The total final

energy demand decreased from 560,91 kWh/m²a to 153,73 kWh/m²a.

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The following Table 2 shows that in addition to the described energetic

efficiency the economic efficiency is given.

Economic efficiency and amortization of energy refu rbishment

measures (storage system):

Table 2: Economic efficiency and amortization calculation of storage system Actual state as well as the two variants in direct comparison:

Figure 7: Primarily energy demand (kWh/m²a) (actual state) (first optimization) (storage system)

Actual annual fuel costs Actual State 259846,92 € Storage system 30349,41 € Boundary conditions Calculatory interest rate 3% Inflation rates Fuel (actual state) 4 % Fuel (first step) 4 % Measures 3,5 % Maintenance 4,5 % Investment tax rate for fiscal depreciation 32 % Calculation parameters Observation period (years) 30 Averaging factors Fuel (actual state) Fuel (first step) Measures Maintenance

Results Investment Total Investment costs 2115251 € Costs of anyway necessary maintenance expenditure 464001 € Costs of energy saving measures 1651250 € Average annual costs of observation Period (30 years) Costs of capital 103287 €/ Year Costs of Fuel 54146 €/ Year Costs of maintenance + 47268 €/ Year Total costs 204701 €/ Year Av. costs of fuel without measures Average annual saving 258885 €/ Year Internal Interest 13,68 % The investment is economically. Its internal rate of return is higher than the calculatory interest rate Armortization time 9 Years Price of the saved kWh 0,0495€/kWh

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Figure 8: Fuel costs ( €/a) (actual state) (first optimization) (storage system) In the present case the overall approach, taking into account all costs and

benefits and regarding the internal interest rate of 13,68 %, is economical.

The energy consumption decreased again.

But the here simulated storage system itself led to no further increase in

profitability (under economic reasons) in comparison to the first optimization

step.

In general, the economic benefit of a storage system, however, inter alia,

depends on the sector of the company and its specific conditions, for

example such as waste heat, or request to air conditioning and chilling.

That means it has to take into account the entire plant engineering and its

energy consumption structure of the whole company.

A storage system needs to be fundamentally designed for each individual

case and for each company especially.

Particularly in the area of energy storage systems there is still a high

development potential and a concomitant high demand for further research.

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3.4 Identified supporting and inhibiting factors in the context of energy efficiency measures

Within the framework of the carried out investigation, the following main

factors towards energy efficiency measures have been identified.

Supporting and inhibitory factors of energy refurbi shment measures:

Monetary reasons:

Supporting factors:

- Cost reduction and increased profit,

- Increasing competitiveness

- Short payback time

- Long-term improvement of the entrepreneurial value chain

- Government assistance programs, tax relief,

- Insurance collectively agreed preferential treatment

- Subsidies and incentives of the State

- Increasing Energy taxes

- Low level of interest rates / Cheap loans

Inhibitory factors:

- Inadequate knowledge of the various financing options

- High investment costs

- Lack of equity capital,

- Long amortization periods

- Still comparatively low energy costs

- Widespread great uncertainty of costs and benefits of energy

efficiency measures

Non-monetary reasons:

Supporting factors:

- Positive impact on the company's image,

- Environmental and climate protection / Carbon reduction

- Increasing public pressure towards the companies

- Implementation of an energy monitoring and management system

- Implementation of an energy manager out of the companies workforce

- Future orientation

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Inhibitory factors:

- Missing or insufficient consultation with regard to energy efficiency

measures

- Lack of technical knowledge

- Lack of information regarding the existing opportunities an their potentials

- Lack of knowledge of energetic interactions

throughout the whole production process

- Current high workload, lack of motivation outside of the own core tasks

- Missing energy management

- Seemingly high personnel expenses for the company

- Lack of knowledge regarding an strategic approach

- Seemingly high expenditure of time

- Misleading medial reports

- Missing policy framework

In summary, it can be concluded that the willingness that is, the overcoming

of innovation blockades for energy efficiency measures will grow with rising

energy procurement costs.In addition, the governmental frameworks should

be improved. Here higher government subsidies and tax incentives could be

an appropriate way.

Furthermore, an improved awareness training (information campaigns etc.

would be necessary e.g. through best practice examples and through

benchmarking approaches.

4 Conclusion and outlook

One of the main conclusions of this thesis is that there was no holistic

approach for SMEs taking into account the latest building physics

possibilities, the organizational possibilities and all the todays state of the art

technologies in addition with the incoming future technoligies. Not at least

regarding the costs respectively the investment and its efficiency.And finally

the combination of them all. Nearly all of the existing companies are not

state of the art. State-of-the-art technologies are available in a large selection

but they remain largely unexploited.

For example more than 80% of the german industrial heat generators are

out of date.

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Many companies have not yet been considered energy efficiency as an

intelligent energy source.As it has been shown, there are a variety inhibitory

factors of energy refurbishment measures that need to be overcome.The

companies should recognize that it is possible to get a sustained reduction of

their energy consumption without supposedly high investment costs or

decreasing their productional efficiency rates.

One of the main problem here are the highly simplified and insufficient

economic calculation methods as they are widespread and repeatedly can be

found in the management offices.

What measures may be technically and economically appropriate carried out

depends in each individual case on the present energy concept.

Objective of economic and technical optimizations are minimum capital

bonded and lowest operating costs.

The amortization of the investment costs, realized through future energy

savings, so to say implies a "money back guarantee".

Rising energy prices combined with decreasing fossil fuel reserves will

continue to strengthen the positive economic impacts for the companies

(Leverage effect). Here, energy refurbishment measures can prove as a

good innovation engine, both for the company itself and for the entire energy

european technology industry as a production factor.

Anyone planning energy refurbishment measures for companies faces major

challenges. Energy-efficient companies taking into account all energy-related

factors that are technically feasible today.

Foresight for the company's development and joint development work by the

entrepreneur, planners, top management, employees, industry and trade is

necessary in order to optimize business over its entire life and operating time

in economic, ecological and functional terms.

Objective is the generation of further synergy effects in which the

total benefit is higher than that of the additive individual performances.

The balancing act between economy and ecology, that is, the balance

between the objectives of efficiency, safety and environmental compatibility

can succeed.

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Sustainability management is a core competency of the future even for the

companies and even for a green and sustainable economy.

Energy efficiency is a win-win situation for all. Improving energy efficiency

will save money, help protect the environment, create new jobs, spur

economic growth as well as creating jobs and technological leadership.

Setting the course in the field of innovative energy technologies in terms of

technological leadership, is accompanied with securing the future of large

parts of the entire european economy. It serves as a sort of investment in the

enhancement of global competitiveness.

Here the use of renewable energies is of particular importance.

In the field of energy efficiency measures a high information and

communication requirement towards the the companies is remaining to

trigger a initial impetus here.

For each type of company the optimal constructional and plant-specific

remediation measures can be determined.

For this reason, a professional status analysis (diagnosis) followed by

measure planning (therapy) taking into account economic aspects is

indispensable. In the future, the companies must be able to use their self-

produced energy (electricity / thermal energy) in large amounts. Without

innovative storage systems self sufficient respectively autark or plus energy

decentralized approach are not possible.

But that does not mean that it is not possible to refurbish an existing

company in an high efficcient way by using todays state of the art

technologies without an energy storage system. This shows the great

advantage of a holistic approach as previously explained.It allows the

companies to plan already today such an high end plus energy approach and

complete it step by step with the upcoming innovative technologies. Here the

decisive aspect is the once done mental anticipation of the whole

process.Only with this approach the implemented refurbishing measures

carried out in the correct sequence lead to the optimum results. With

adequate advice and supervision the company of the future so to speak the

“company 4.0” is possible not only with regard to energy technology.

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In general:

There is not one special energetic measure which is equally applicable for

every company, but there are for each company its specific measures.

Energy efficiency has to be understood as an intelligent energy source

(see also Hofmann, Peter, 2014“Energy efficiency and cost reducing

applications in companies p.89) [5].

So through the research and developments of this study, that was based i.a.

on previous available knowledge, it was possible to create new knowledge.

Further research demand:

Particularly in the area of energy storage systems there is still a high

development potential and a concomitant high demand for further research

above all i.a. regarding their storage capicity and costs.

Scientific work, is not only an unilaterally approach from one side but from

many sides taking into account all of the latest scientific state to reach a

justifiable conclusion.There are also impulses and knowledge transfer from

industry into research and science as well as vice versa. Relationship

between knowledge and application can be created. Additional to improve an

constructive exchange between knowledge-oriented and application-oriented

research. Moreover there is an increasing demand for quaternary education

not only regarding energy efficiency. From the results of this study further questions can be derived also relevant

for the other engineering disciplines, for example i.a. the whole construction-

or power-engineering industry, for control- technology or for increasing use of

renewable energies in the companies.

Finally:

The energy will be (without a functioning nuclear fusion) increasingly the gold

of the 21st. century. Saving energy as well as energy efficiency in companies

is the present.

The future, however, are the energy-producing, energy-autonomous and

plus energy companies.

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List of author´s publications:

Hofmann, P.: Thermal energy storage system technologies- Quo vadis?. Journal of interdisciplinary economic research. Volume 2013/1. pp.72-77. ISSN: 2196-4688.

Hofmann, P.: Energy efficiency and cost reducing. Applications at companies. Journal of interdisciplinary economic research. Volume 2014/1. pp.89-94. ISSN: 2196-4688.

Hofmann, P.: Electrical energy storage system technologies- Quo vadis?. Journal of interdisciplinary economic research. Volume 2015/2. pp.135-139. ISSN: 2196-4688. Šály, V. ─ Packa, J. ─ Váry, M. ─ Perný, M. ─ Hofmann, P.: Small Photovoltaic System.Časopis EE, VOL 20. NO 5/S, 2014, 1-4. Gleser, A. – Hofmann, P.: Change Management in Production Processes: Financial Aspects of RFID-Projects; Change Management of Innovation: Strategic - Design - Implementation, Arona: Eastern Institute for Integrated Learning in Management University, 2015. 11 p. ISBN: 978-3-86468-945-1. Šály, V. - Hofmann, P. - Packa, J. - Perný, M.: Improving energy efficiency in small and medium-sized companies. In ELOSYS. Elektrotechnika, informatika a telekomunikácie 2015 [elektronický zdroj] : Konferencia s medzinárodnou účasťou. Trenčín, Slovakia. 13. – 15. október 2015. 1. vyd. Bratislava : Nakladateľstvo STU v Bratislave, 2015, CD-ROM, pp. 121-123. ISBN: 978-80-227-4437-9. Hofmann, P. - Šály, V.: Needs and possibilities for improving energy efficiency in small and medium-sized enterprises. In Power engineering 2016. Renewable Energy Sources 2016 : 6th International Scientific Conference. Tatranské Matliare, Slovakia. May 31 - June 2, 2016. 1. vyd. Bratislava: Slovak University of Technology, 2016, pp. 73-76. ISBN: 978-80-89402-82-3.

František J. ─ Perný, M. ─ Šály, V. ─ Giemza, M. ─ Hofmann,P.: Microwave supported treatment of sewage sludge. Journal of ElectrIcal Engineering, VOL 67 (2016), NO4, 286–291ISSN 1335-3632, On-line ISSN 1339-309X© 2016 FEI STU.

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List of Sources: [1] Bayerisches Landesamt für Umwelt (2009):“Leitfaden für effiziente Energienutzung in Industrie undGewerbe“, Augsburg, p.8, www.Ifu.bayern.de. [2] Recknagel, Sprenger, Schramek (2003/2004): “Taschenbuch für Heizung und Klimatechnik“, 71.Auflage,Oldenbourg Industrieverlag München, www.oldenbourg.de,ISBN:3-486-26543-2. [3] Niehues, Dr.K.(1997):„Unternehmenserfolg statt hausgemachter Unternehmenskrisen“ KMU-Institut GmbH, Waldeyerstr. 61, 48149 Münster,www.kmu-institut-gmbh.de. [4] Dena GmbH (2009):“Handbuch für betriebliches Energie- management“, German Energy Agency, Chausseestraße128a, 10115 Berlin, p.35/p.37, www.dena.de, ISBN:978-3-9812787-7-4. [5 Hofmann, P. (2014):“Energy efficiency and cost reducing applications in companies“, Journal of interdisciplinary economic research,Volume 2014/1. pp.89-94. ISSN: 2196-4688.